Servo motor driven scroll pattern attachments for tufting machine with computerized design system and methods of tufting
First Claim
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1. A method of creating and tufting a carpet pattern comprising the steps of:
- selecting pattern parameters of width, length, a relatively high pile height and a relatively low pile length, for stitches on a computer display;
creating a border pattern for at least one border to surround a central image;
scanning an image to create a digital image;
processing the digital image by a computer to calculate corresponding yarn heights and yarn feed increments for a plurality of colors of yarns in a carpet pattern to create pattern information;
inputting the pattern information into a master controller of a multi-needle tufting machine;
threading yarn ends of said plurality of colors of yarns from a yarn supply through a yarn drive array to a plurality of laterally spaced needles;
reciprocating the plurality of laterally spaced needles threaded with said plurality of yarns through a backing fabric fed longitudinally from front to back through the tufting machine;
sending information relative to the position of the plurality of needles to the master controller;
the main controller sending information relative to the amount of yarn to be fed for the next stitch to the yarn drive array;
operating a looper mechanism in synchronized cooperation with the plurality of needles to seize loops of yarn tufted through the backing fabric;
thereby forming a tufted carpet having;
a top surface on the backing fabric, a bottom surface and an outer perimeter encompassing a center portion;
a first border surrounding the center portion comprising a first plurality of bights on the outer perimeter of the top surface of the backing fabric;
wherein the plurality of bights comprising said first border is formed by feeding stitches of yarn in at least three distinct increments of length.
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Abstract
The present invention provides alternative scroll-type yarn feed attachments for tufting machines characterized by independent servo-motor control of sets of yarn feed rolls, and a software design system to facilitate use of the attachment to produce novel patterns and photo images.
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Citations
20 Claims
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1. A method of creating and tufting a carpet pattern comprising the steps of:
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selecting pattern parameters of width, length, a relatively high pile height and a relatively low pile length, for stitches on a computer display;
creating a border pattern for at least one border to surround a central image;
scanning an image to create a digital image;
processing the digital image by a computer to calculate corresponding yarn heights and yarn feed increments for a plurality of colors of yarns in a carpet pattern to create pattern information;
inputting the pattern information into a master controller of a multi-needle tufting machine;
threading yarn ends of said plurality of colors of yarns from a yarn supply through a yarn drive array to a plurality of laterally spaced needles;
reciprocating the plurality of laterally spaced needles threaded with said plurality of yarns through a backing fabric fed longitudinally from front to back through the tufting machine;
sending information relative to the position of the plurality of needles to the master controller;
the main controller sending information relative to the amount of yarn to be fed for the next stitch to the yarn drive array;
operating a looper mechanism in synchronized cooperation with the plurality of needles to seize loops of yarn tufted through the backing fabric;
thereby forming a tufted carpet having;
a top surface on the backing fabric, a bottom surface and an outer perimeter encompassing a center portion;
a first border surrounding the center portion comprising a first plurality of bights on the outer perimeter of the top surface of the backing fabric;
wherein the plurality of bights comprising said first border is formed by feeding stitches of yarn in at least three distinct increments of length. - View Dependent Claims (2, 3, 4, 5, 6, 7, 16, 17, 18, 19)
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8. A tufted carpet comprising:
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(a) a generally planar backing fabric having a top surface, a bottom surface and an outer perimeter encompassing a center portion;
(b) a first border surrounding the center portion comprising a first plurality of bights on the outer perimeter of the top surface of the backing fabric;
(c) a second border surrounding the center portion visually distinct from and located interior of said first border, and comprising a second plurality of bights on the outer perimeter of the top surface of the backing fabric;
(d) wherein the plurality of bights comprising at least one of said first and second borders is formed by feeding stitches of yarn in more than three distinct increments of length. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15, 20)
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Specification